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Thread: Overhaul and upgrade to an O-360

  1. #31
    Administrator Steve Pierce's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    I send those nuts and other engine hardware to the prop shop for plating and bake.

  2. #32
    JPerkins's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    I'll be sanding the base of the nuts to bare steel before installing. Plan on painting the enamel on once everything is together as an assembly.

    Should have done what Steve's does. Will do next go around.

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    Jason Perkins

  3. #33
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    Default Re: Overhaul and upgrade to an O-360

    Something I managed to find time for was building the air box mounting flange. 1/8" 4130, used a 2" hole saw to get the radius in the corners, then a die grinder to clean it up.
    Cut a strip of .062" and worked it into it's shape. Then TIGed it together.

    Then the fun of removing the old mounting flange as it is brazed on. Figured out if I soften the brake with a torch then give a blast of air it will blow it off. Popped off the old flange and then welded the new one in place. Last thing to do was remove the material from inside. Did this with a die grinder and dressed with a file. When all this was done I layed the mating surface of the flange in a belt sander to dress it up and get this tiny bit of warp out of it.

    Last photo is the O-320's carb next to the O-360's. Slight difference.20180508_185400.jpg20180508_191118.jpg20180508_202938.jpg20180511_193534.jpg20180511_193537.jpg20180511_201317.jpg20180511_201520.jpg

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    Jason Perkins

  4. #34
    JPerkins's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    Christmas came! Got all the little pieces for the overhaul from AERO Instock. Im also the new proud father of shiny new(ly overhauled) MA4_5SPA carburetor! I was pretty excited about that. Second Christmas will come when the Aircraft Spruce order comes in.

    Walt I used Hoppes on the primers and suction screen and was mildly blown away, thanks for the suggestion. To give you an idea, everything looked like the brass components on the primers lines prior to soaking and brushing with the Hoppes no. 9.
    Today I pulled the old engine from the bird, then the firewall. It will require some modifications for the engine upgrade, and I decided it would be easiest off the plane.20180516_173006.jpg20180516_173947.jpg20180518_190342.jpg20180519_115553.jpg20180519_105643.jpg20180519_115600.jpg

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    Jason Perkins

  5. #35
    walt.buskey's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    Hey, you're most welcome, and glad this newbie was able to contribute!

    Forget where I learned about Hoppe's and brass (might have been on this forum, actually), but yes, I learned that it works very well on brass fittings, too. (Besides, it smells nice!) I also used it on my primer injector things.

    Be glad you din't find a primer line like the one I found -- some idiot had tried to use a slip-on ferrule instead of the hemispherical union cone and twisted the &%$ out of the 1/8" copper tubing trying to tighten it up enough so it wouldn't leak:

    DSC04150.jpg

    ...Well, true, it didn't leak.....
    Last edited by walt.buskey; 05-20-2018 at 06:28 AM.

  6. #36
    JPerkins's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    So I pulled the firewall to make it easier to do the modifications. The biggest one being the dish to make room for the oil filter.
    So I got out my body hammers and dollies, looked at the blue prints and hammered one out.
    Next step was to pull the firewall blanket. It was just a little rough. Will be doing something new upon assembly. Cleaned up the back side with paint stripper to get the glue off, then M.E.K. and a scotchbrite for the rest.
    Flipped it over, layed out the hole and cut it. Had to move the p-lead connectors down just a smidge for it to fit. Then it was just a matter of drilling and screwing the recess bowl into place. All the holes circled with sharpie are to be plugged as they are no longer used. And when my Aircraft Spruce order comes I'll have the stainless sheet to make patches for other areas.20180520_132645.jpg20180520_132716.jpg20180519_185844.jpg20180519_190156.jpg20180520_121642.jpg20180520_132927.jpg20180520_133710.jpg20180520_144005.jpg

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    Jason Perkins

  7. #37
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    Default Re: Overhaul and upgrade to an O-360

    Cleaned up the cabin heat air boxes. Found a little tapping on a socket worked great to straiten up the tubing. Then a little sandblasting. Found a crack, TIGed it, and some paint. Ready for firewall reassembly.20180521_165317.jpg20180521_165324.jpg20180521_165559.jpgAttachment 13528

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    Jason Perkins

  8. #38
    tnowak's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    You made that dish out of a flat sheet of aluminum with two hammers and one dollie? Impressive.
    Wish I had those metalworking skills!
    Tony N

  9. #39
    Stephen's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    Beautiful work Jason. What type of aluminum did you use?
    "You can only tie the record for flying low."

  10. #40
    JPerkins's Avatar
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    Default Re: Overhaul and upgrade to an O-360

    Ok I gotta level with ya. I thought someone would have called me on my baloney.
    I was looking at the blueprints over coffee one morning, and thought "crap, that'll take a day and a half to fab that up". Then I got up and fed the dogs and was like "wait a minute".
    It's actually a stainless dog bowl, sorry to lead you on but I couldn't resist!

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    Jason Perkins

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